Method of and means for working moldable matter



Dec. 31A, 1929. J. E. BoYNTON METHOD OF AND MEANS FOR WORKING MOLDABLE MATTER Original Filed June 13, 1924 2 Sheets-Sheet 1 -wam "wyf LMLSM Dec. 3i, 1929. 1. E. BOYNTON METHOD OF AND MEANS FOR WORKING MOLDABLE MATTER 2 Sheets-Sheet 2 Original Filed June 13, 1924 Patented Dec. 31, 1929 UNITED STATES PATENT OFFICE vJOHN EDSON BOYNTON, F OAK PARK, ILLINOIS, ASSIG-NOR TO WESTERN ELECTRIC COMPANY, INCORPORATED, OF NEW YORK, N. Y., A. CORPORATION OF NEW YORK METHOD OF AND MEANS FOR WORKING MOLDABLE MATTER Application led Junel, 1924, Serial No. 719,817. B .enewed August 14, 1929.

This invention relates to a method of and means for Working moldable matter and more particularly to a method of and means for sheathing a core with moldable matter.

The invention is particularly adapted to be employed in the sheathing of cable cores. Heretofore, it has been the almost universal practice to apply the metallic sheath to a cable core by means of a hydraulic extrusion press having a cylinder adapted to liold a quantity of the metal to be extruded. This met-al is delivered to the cylinder in the fused state and must be permitted to cool before the press is set in operation. After the metal has been extruded, the ram of the press must be backed out of the cylinder so that the cylinder may be relled. The period of activity of the press is invariably less than the period of preparation therefor. The general 'eliciency of the method is less than 50% of that of a v. method which is substantially continuous in its nature and not limited to the of a hydraulic cylinder or the like.

An object of the invention is to provide a method and apparatus whereby-tubing can capacity vbe manufactured at a comparatively low cost.

Another .object ofthe invention is to provide a method of and apparat-us for forming tubing without the use of high pressures.

Still another object of the invention is to form a metallic tube continuously.

Still another object of the invention is to sheathe a core continuously.

One embodiment of the invention is ada-pted to sheathe a cable core and comprises means for carrying a supply reel and a takeup reel bodily around an axis of rotation so that a cable core which is being withdrawn from t-he supply reel by the take-up reel may wrap a metallic ribbon around itself as it ypasses to the take-up reel, the metallic ribbon being molded contemporaneously and being fused into an imperforate covering for the core before the core is wound upon the takeup reel. The supply reel and the take-up reel are\ each rotatably mounted in one .of a pair of ring-shaped members which are coaxially disposed in spaced lrelation and so supported upon a plurality of rollers that they may `reel may be Withdrawn therefrom and rewound upon the take-up reel. The cable c ore is preferably constrained to traverse a portion of the axis of rotation of the annular members as it passes from one reel to thel other. This enables the core to wrap itself smoothly and evenly in ametallic sheath which is applied in ribbon form tothe core. The metallic ribbon is Wound in helices around the core, the angle at which the ribbon is applied to the core being controlled by centrifugally operated mechanism responsive tothe speed at which the core is advanced to the take-up reel. A heating unit is employed to fuse the helices to each other as the sheathed core passes to the take-up reel. Cooling means is disposed in close proximity to the 'heating unit and is adapted to solidify the fused portions of the sheath after they leave the heating unit. During the operation ofthe apparatus, the sheathed core which is being Wound around the take-up reel is balanced by a countervveight which is adjustably mounted with respect to the take-up reel* and is brought into a plurality of adjusted positions with respect thereto by means actuated by the means for driving the Atake-upreel. Similar means is provided for balancing the cable core on the supply-reel. t

The metallic ribbon is molded by apparatus comprising a receptacle adapted to hold a supply of fused metal. The-receptacle is provided With a spout through which the fused metal may gravitate and ilow out upon a pivotally mounted guide or table, the fused metal -in the receptacle and spout being held at a is desired to impart to the ribbon. The solidifying ribbon of metal passes between a pair of rollers adapted to roll or to gauge the metal to a uniform thickness. They function in this manner when the metal tends to pile up as it l be substantially free from oxide and will be in a condition which facilitates the operation of fusing the helices to each other. The rotary cutters or knives are mounted on the pivotally mounted guide or table, the guide or table being operatively connected to the aforementioned centrifugally operated mechanism which swings the guide or table into .positions wherein it feeds the metallic ribbon to the cable core at an angle corresponding to the speed at which the core is advanced to the take-up reel.

The objects of the invention are more yclearly set forth in the following detailed description, reference being had to the accompanying drawings, wherein Fig. 1 is a plan view of apparatus embodying the invention;

Fig. 2 is a section taken on line 2-2 of Fig. 1;

Fig. 3 is a section taken on line 3-f-3 of Fig. 1;

Fig. 4 is a section taken on line 4-4 of Fig. 1;

Fig. 5 is a section taken on line 55 of Fig. 4, and

Fig. 6 is a section taken online 6-6 of Fig. 1.

It is believed that a complete understanding of the improved method will be procured from a description of the apparatus by means of which the method may be practiced.

Referring tothe drawings, the reference character 10 designates a receptacle for holding a supply of metal in a fused state from which a metallic element in ribbon form as indicated at 11 is molded. The receptacle 1() may be heated by any suit-able means (not shown). The metallic ribbon 11 is supplied to a cable core 12 which is drawn from a supply reel 13 by a take-up reel 14, means being interposed between the reels for forming the metallic ribbon into an imperforate sheath for the core. The supply reel 13 and the take-up reel 14 are carried by annular members 17 and 18, respectively. The annularmembers 17 and 18 are coaXially arranged in lspaced relation and are supported upon a plurality of rollers 19 which permit the annular members to be rotated about a common axis. The rollers 19 are rotatably journaled upon a plurality of shafts 20 and 21 which are in turn rotatably journaled in a bed or floor 22 upon which the apparatus rests. A plurality ofpinions 24 rigidly secured upon the shaft 20 mesh with gears 25 and 26 formed integrally with the annular members 17 and 18, respectively. The shaft 2O may be rotated by any suitable means (not shown) and will in turn rotate the annular members 17 and 18 in unison through the medium of the pinions 24 and the gears 25 and 26.

Referring now to Fig. 2, the take-up reel 14 is mounted upon a shaft 28 and is constrained to rotate therewith.4 The shaft 28 is rotatably journaled ina plurality of tubular brackets 29. secured to the annular member 18, the annular member 18 being provided with apertures 30 which permit the shaft to be withdrawn from the annular member when the reel 14 is to be replaced. vA sleeve 31 splined upon the shaft 28 by means of a feathered key 32 has an integral worm gear 33 meshing with a worm 34 rigidly secured to a shaft 35 which is rotatably journaled in a bearing bracket 36 rigidly secured to the annular member 18. A pinion 40 keyed to the shaft 35 meshes with a stationary internal gear 41 which is carried by a plurality of uprights 42. It is obvious that rotation of the tion of the shaft 28 through the medium of the worm gear 33, the worm 34, the pinion 40 and the gear 41. The arrangement is such that the take-up reel 14 will draw the cable core 12 from the supply reel 13 and wind the cable core around itself.

The take-up reel 14 is counter-balanced by a weight 43 threaded upon a rod 44 which is rotatably journaled in a bearing 45 rigidly secured to the inner surface of the annular member 18. A worm gear 46 fastened to the rod 44 meshes with a worm 47 secured to a shaft 48, the shaft 48 being journaled in a plurality of bearings 49 'secured to the annular member 18. 48 has one end of a cord 51 secured thereto, the other end of the cord 51 being provided with aneye 52 adapted to be positioned upon a pin 53 projecting from the sleeve 31. During rotation of the annular member 18 the sleeve 31 will, of course, withdraw the cord 51 from the drum and thus rotate the drum together with a shaft 48 and the yworm 47. The motion of the worm 48 is imparted to the worm gear 46 which causes the rod 44 to displace the weight 43 along the rod in a direction away from the axis of rotation from the annular members 17 and 18, the weight 43 being held against rotation around the axis of the rod 44 by a bracket 55 which engages a lug 56 projecting from the weight. The purpose of this construction is to compensate for the weight added to the take-up reel 14 when the i annular member 18 is accompanied by rota- A drum 50 secured to the shaft cable core is drawn from the supply reel 13 and wound upon the take-up reel 14. During this operation, the weight 43 will draw away from the axis of rotation of the annular members 17 and 18 at a rate of speed which is proportional. to the rate of speed with which the cable core is wound upon the takeup reel. To restore the weight 43 to its initial position and at the same time to rewind the cord 51 upon the drum 50, the operator need only remove the eye 52 from the pin 53 and then rotate the drum 50 in a counterclockwise direction (Fig. 2).

The supply reel 13 is mounted upon a shaft 60 rotatably journaled in tubular bearings 61 secured upon the inner surface of the annular member 17, the annular member 17 being provided with apertures 62 which permit the shaft to be removed from the annular member when the supply reel 13 is to be replaced. A weight 63, substantially identical tothe aforementioned weight 43, is adapted to be displaced with respect to the common axis of the annular members 17 and 18 by means of mechanism which is substantially.

identical with the mechanism for displacing the weight 43. However, in this instance zthe arrangement is such that the weight 63 approaches the axis of rotation as the cable core 12 is withdrawn from the supply reel 13.

It is readily understood that if a supply reel 13 and a take-up reel 14 are mounted in 'the annular members 17 and 18, respectively,

the apparatus may be operated to have the take-up1 reel 14 withdraw the cable core 12 from t e supply reel and the cable core will be rotated around a .common axis of the annular members. This enables the cable core to wrap around itself material which is supplied to it. In this embodiment ofthe invention the cable core 12will wrap the metallic ribbon 11 around itself, the arrangement of the apparatus being such that the metallic ribbon 11 is applied in a plurality of helices around the core.

As shown in Fig. 1 the cable core 12 ispreferably led through a guide 65 when it leaves the supply reel 13, the guide being adapted to bring a section of the cable core into a position wherein its longitudinal axis coincides with the axis of rotation of the annular members 17 and 18. The metallic ribbon 11 is supplied to the core directly after it has been drawnthrough the guide 65.

A heating unit 661s disposed intermediate the. annular member 18 and the p'oint at which the metallic ribbon 11 is supplied to the cable core. The heating unit 66 is provided with an annular passage 67 through which the core and its covering of metallic ribbon are advanced on their way to the take-up reel. The heating' unit 66 comprises a block 68 mounted upon a frame 69. A tubular resistor in helical form is disposed in the block 68 and forms a portion of the wall of the passage 67.

vto the resistor.

The resistor 70 is insulated from the block 68 and has its ends connected to a pair of binding posts 71 projecting from the upper surface of the block 68. The binding posts 71 provide means whereby the resistor 70 may be connected to' any suitable source of electrical energy and heated to a temperature which willbe suicient to fuse the metallic ribbon 11 when it comes in close proximity The lead of the helical resistor 70 is substantially equal to the lead of the helices of metallic ribbon 11 applied to the cable core'. The apparatus is so arranged that the contiguous edges of each two adjacent helices of the metallic ribbon will move along the inner surface of the resistor, which surface is suciently wide to cause the edge -portions of the metallic ribbon to fuse but is prefenably too narrow to fuse the entire width of the metallic ribbon as if the entire width of the ribbon is fused the concentricity of the ribbon relative tothe core may be destroyed. A plurality of pipes 72 connect the resistor 70 to any suitable source (not shown) of cooling Huid so that a cooling iiuid its temperature quickly if the operator so desires. The left hand end (Fig. 1) of the block 68 is provided with an annular chamber 73 which is connected by means of a plurality of. pipes 74 to a suitable'supply (not shown) of cooling fluid. It is apparent that the portions of the metallic ribbon 11 which are fused as the ribbon is drawn past the resistor 70 will be solidified by the cooling uid in the annular chamber 73 and the metallic ribbon will become an imperforate sheath for the core.

The means for forming the metallic ribbon 11 from the fused metal in the receptacle 10 comprises a spout 75 through which-the fused metal may gravitate to the discharge orifice 76 of the spout (Fig. 4).- The discharge ori- Iice 76 is of a shape substantially conforming to the shape it is desired to impart to the metallic ribbon 11. The fused metal is held at a temperature whichpermits it to solidify ferred embodiment of the invention is received between a plurality of rolls 77 and 78 when it leaves theoriice. The roll 78 is provided with end flanges 79 which fit snugly against the end surfaces of the roll 77.

As shown in Fig. 5 the rolls 77 and 78 mounted upon a plurality of shafts 80 and 81, respectively, the shafts 80 and 81,being rotatably journaled upon a guide or table-82 which has one` of its ends rigidly secured to a vertically disposed shaft 83 rotatably journaled in the upper end of a bearing member 84. The shaft 80 is driven by any suitable means (not shown) and is provided with a gear 85 meshing with a gear 86, rigidly secured to a shaft 8l. The rolls 77 and 78 are spaced apart a distance which is substantially equal as it iows from the orifice 76, and in the preto the thickness of the metallic ribbon 11 and the length of the roll 77 is substantially equal tothe width of the metallic ribbon. Therefore, .the rolls 77 and 78 tend to gauge the thickness and width of the ribbon, particularly so when the fused matter tends to pile up as it leaves the spout 75. Itis obvious that the rolls would withdraw the metallic ribbon from the spout 75 should the fused metal in the spout solidify just before it reaches the orice 76. A plurality of heating units 87 disposed around the spout 75 providesmeans for keeping the metal in a fused state as it passes through the spout, the flow of fused metal through the spout being controlled by a valve 88.

A pair of rotaryblades or knives 90 are provided for trimming the edges of the metallic ribbon 1l directly before it is applied to the cable core. One purpose of this construction is to prepare unoxidized surfaces upon the metallic ribbon so that adjacent helices of the ribbon may beefectively fused together as` they pass the resistor 70. The rotaryy knives 90 are secured to a shaft 91 rotatably jour naled upon the free end of the guide or table 82. A sprocket 93 keyed around the shaft 91 meshes with a sprocket chain 94 which in turn meshes with a sprocket 95 rigidly secured to the shaft 80.

To compensate for the increasing speed at which the core is advanced when the sheathed core piles up on the take-up reel 14, means 4is provided for swinging the guide or table 82 around the axis of the shaft 83 so asto deliver the metallic ribbon 11 to the core 12 at an angle corresponding to the speed of the core. This means comprises a plurality of grooved rollers 96, 97 and 98 adapted to engage the sheath of core as it leaves the heat* ing unit 66. The grooved rollers 97 and 98 are rotatably journaled upon a plurality of shafts 99 projecting from the frame 69, and the grooved roller 96 is rotatably journaled upon a pin 100 carried on the yfreeend of a lever 101 pivotally mounted on the frame 69 by a pin 102. 'A plurality of helical springs 103 urge the grooved roller 96 toward the rollers 97 and 98 and so cause vthe sheathed core which passes between the rollers to drive the rollers 97 and 98. One end of each spring 103 is secured to the pin 100 and the other end thereof is secured to one of the shafts 99. Each of the rollers 97 and 98 has a gear 104 yformed integrally therewith and adapted to mesh with a pinion 105 journaled upon a pin 106 projecting from the frame 69. A gear 107 mounted upon the pin 106 and constrained to rotate with the pinion 105 meshes with` a Cpinion 108, the pinion 108 being'rigidly secure naled Lin the` frame 69. f

As shown in Fig. 3 the shaft 109 has a disc 110 secured to it on its upper end. A plurality of levers 111 are pivotally secured to on a shaft 109 which is rotatably jour\ the disc 110 by means of a plurality of pins 112, the axes of the pins 112 being equi-distantly spaced from each other and from the axis of the shaft 109. Each lever 111 is provided with a weight 113 at its outer end and with a grooved pin 114 intermediate its ends.

A belt 115 is trained over the pins 114 and' over a sheave 116 journaled on a pin 117 proj ecting from the under surface of the guide or table 82. It will be readily understood that when the disc 110 is rotated, the centrifugal force generated by the weights 113 on the levers 111 tends to bring the levers 111 into radial positions with respect to the axis of the shaft 109 and thus tends to move the grooved pins 114 away from the axis. Therefore, any increase in speed lin the disc 110 will be accompanied by a tightening of the belt 115 which will then swing the guide or table 82 in a counter-clockwise direction (Fig. 1) against the action of a tension spring 118. If there isa decrease in speed in the disc 110, the guide or table 82 will be angularly displaced in a clockwise direction '(Fig. l) by the tension spring 118.

In the operation of the apparatus, the supf ply reel 13 carrying a supply of cable core 12 is mounted in the annular member 17 and an empty take-up reel 14 being mounted in the annular member 18. The cable core 12 is then threaded through the guide 65,. the heating unit 66 and between the grooved rollers 96, 97 and 98. The forward end of the cable core is then secured to the take-up reel 14 or a short piece of steel cable or the like is utilized to secure the end of the cable core to the takeup reel. The valve 88 is then opened and thel metallic ribbon 11 issuing from the spout 75 is applied to the cable core. After the operator has arranged the first few Wraps of the metallic ribbon 11 around the cable core and has threaded the wrapped section of the core through the heating unit 66 and the grooved rollers 96, 97 and 98, the apparatus is set in operation. This, of course, includes theact of closing the circuit for the resistor which fuses the convolutions of the metallic ribbon 11 to each other. The cooling fluid admitted to the annular chamber 73 in the block 68 serves to solidify the fused metal before it is drawn from the block. Should it be necessary at any time to stop the apparatus, it is preferable that a cooling fluid be admitted to the resistor4 70 by way of the pipes 72 so that that portion of the metallic ribbon 11 which is in contact with the resistor will not remain in a fused state and so heat an adjacent portion of the ribbon that it flows out of the block 68. Of course the circuit for the resistor 70 is opened when the apparatus is brought to a full stop.

As the `receptacle 10 may be refilled during the operation of the apparatus whenever it becomes necessary to do so, the etlicienc of the apparatus greatly exceeds that o an hydraulic eXtruding press. The method embodying the invention is continuous with respect to any given length of cable core which may be placed in the apparatus.

What is claimed is:

l. A method of constructing a tube, which method consists in molding an element from fused metal, contemporaneously therewith coiling the element, and in fusing portions of theucoiled element to form an imperforate wa 2. A method of sheathing a core, which method consists in molding a metallic element, contemporaneously causing relative rotary movement between the element and a core whereby the element is applied to the core, and in contemporaneously therewith fusing portions of the element to each other to form an imperforate sheath.

3. A method of sheathing a core, which method consists in molding a metallic element, contemporaneously causing relative ro- -tary movement between the element and a core whereby the element'is applied to the core, contemporaneously therewith fusing portions of the applied element to each other, and in contemporaneously subjecting the fused portions to the influence of a cooling fluid to solidify the fused portions.

ll. A method of sheathing a core, which method consists in molding a sheathing material therefor from fused metal, contemporaneously applying the sheathing material to the core to form a plurality of helices thereon, and in fusing adjacent helices to each other.

I method consists' in flowing 5. A` method of forming a tube, which method consists in flowing fused metal through an orice in such manner and at such a temperature that the metal solidies, as it -leaves the orifice, into a shape conforming substantially to the shape of the orifice, and contemporaneously coilin the solidified metal into a tubular formation.

core, which method consists in molding an element from fused metal, and in contemporaneously applying the element to the core by a combined rotary and longitudinal movement of the core.

10. A method of continuously sheathing a core, which method consists in molding an element from fused metal, contemporaneously Winding the element around the core, and in contemporaneously fusing portions of the winding. 5

11. In metal-working apparatus, the combination with means for molding a metallic element, of means for contemporaneously coiling the element and means for contemporaneously fusing portions of the element to each other.

12. In apparatus for sheathing a core, the combination with means for molding a metallic sheath in ribbon form, of means for contemporaneously winding the sheath upon the core, means for contemporaneously advancing the core, and means for contemporaneously fusing portions of the sheath to secure the sheath upon the core.

13. In apparatus for sheathing a core, means for advancing the core, means for contemporaneously rotating the core around its longitudinal axis, means for contempora-'- neously molding a metallic strand, means for contemporaneously applying the strand to the core, and means responslve to the speed at which the core is advanced for controlling the angle at which the strand is applied to the core.`

In witness whereof, I hereunto subscribe my name this 29th day ofv May A. D. 1924i. JOHN EDSON BOYNTON.

6. A method of sheathing a core which i method consists in .flowing fused metal through an orifice in such manner that the.

metal solidies as it leaves the oriice, and in contemporaneously winding the solidified metal around the core.

7 A method of sheathing a core, which fused metal through an orifice in such manner that the metal solidies as it leaves the orifice, contemporaneously winding the solidified metal aroundthe core, and in fusing adjacent convolutions of the Winding to each other.

8. A method of sheathing a core, which method consists in molding an element, contemporaneously preparing unoxidized s faces upon the metallic element, windin the element around the core, and in fusing adjacent convolutions of the winding to each other.

9. A method of continuously sheathing a 

